Tacky base material with powder thereon

ABSTRACT

A synthetic material comprises 
     a base material providing at least one tacky surface that is tacky at a temperature of less than about 80° C.; and 
     a powder layered upon the base material which has a substantially non-tacky surface at a temperature of up to about 40° C. and exhibits adhesiveness at a temperature of greater than 120° C. The powder includes one or more correspondence components such as an epoxy resin which is either i) substantially identical to a component of the base material, or ii) the monomer or oligomer configuration of the correspondence component is substantially identical to a component of the base material but may have a greater molecular weight or longer polymer chain structure, or iii) is insubstatantially different from a component of the base material (e.g. has the same characteristics and a similar structure but a higher molecular weight).

FIELD OF THE INVENTION

The present invention relates to an improved synthetic material, andarticles incorporating the same. More particularly, the presentinvention relates to a synthetic material having a tacky surface and anon-tacky surface wherein a powder has been disposed upon a base tackymaterial for forming the non-tacky surface.

BACKGROUND OF THE INVENTION

It is generally known to apply a synthetic material such as anexpandable material, a structural material, a foamable material or thelike to an article of manufacture for imparting strength, acousticdamping characteristics or the like to the article. Such syntheticmaterials are frequently used in articles such as buildings, containers,automotive vehicles or the like. For application purposes and for otherreasons, it may be desirable for one surface of such a syntheticmaterial to be tacky while another surface of the material issubstantially non-tacky. For example, and without limitation, anindividual applying a synthetic material to an article typically desiresa non-tacky surface appropriate for handling of the synthetic materialand a tacky surface for adhering the material to an article. Suchsynthetic materials, however, can present difficulties. For example, thematerials may be difficult to form, may cause substantial amounts ofwaste or the like. As another example, it may be difficult for thematerials to maintain their adhesive properties. Thus, there is a needfor a synthetic material having at least one tacky surface and at leastone substantially non-tacky surface wherein the material overcomes oneor more of the difficulties of prior synthetic materials.

SUMMARY OF THE INVENTION

The present invention is directed to a synthetic material, a method offorming the synthetic material, articles incorporating the syntheticmaterial and methods of applying or using the synthetic material. Thesynthetic material typically includes a base material that is tacky at atemperature of less than about 80° C. for providing at least one tackysurface. The synthetic material also typically includes a powder layeredupon the base material wherein the powder preferably provide asubstantially non-tacky surface at a temperature of up to about 40° C.and exhibits adhesivity at a temperature greater than 120° C. In onepreferred embodiment, the base material is epoxy-based and the powderincludes at least one or more epoxy correspondence components, whichcorrespond to component in the base material.

For one method of use for the present invention, the synthetic materialis used to reinforce or provide acoustical damping to a member of anarticle of manufacture (e.g., an automotive vehicle). According to themethod a base material is provided wherein the base material includesprimarily epoxy components and is tacky at a temperature of about 23° C.A powder is dispensed upon the base material to form a syntheticmaterial with at least on substantially non-tacky surface and at leastone tacky surface. The powder preferably includes primarily epoxy basedcorrespondence components and the powder is preferably substantiallynon-tacky at a temperature of about 23° C. and exhibits adhesivity at atemperature greater than 80° C. One formed, the synthetic material isapplied to a member of an article of manufacture preferably bycontacting the substantially non-tacky surface such that the tackysurface is contacted with the member.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claims,and drawings, of which the following is a brief description:

FIG. 1 is a sectional view of an exemplary synthetic material accordingto one aspect of the present invention; and

FIG. 2 is a diagram of an exemplary method of forming synthetic materialaccording to another aspect of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon an improved synthetic material,articles incorporating the material and a method for forming thematerial. Preferably, the method enables formation of the syntheticmaterial with a tacky surface and a substantially non-tacky surface. Itis also preferable for the synthetic material to assist in providingstructural reinforcement, adhesion, sealing, acoustical dampingproperties or a combination thereof within a cavity or upon a surface ofone or more structural members (e.g., a body panel or frame member) ofan article of manufacture (e.g., an automotive vehicle). The syntheticmaterial may be applied directly to structural members of articles ofmanufacture or it may be applied to a first member (e.g., a reinforcingmember) followed by application of the member and the material to astructural member.

Generally, the synthetic material of the present invention includes asubstantially non-tacky powder that is applied to a tacky base material.This powder is applied to (e.g, layered upon) at least one of aplurality of surfaces of the base material. In this manner, it ispossible to form the synthetic material with at least one tacky surfaceand at least one substantially non-tacky surface. Referring to FIG. 1,there is illustrated an example of a synthetic material 10 according tothe present invention. The synthetic material includes a base material12 and a powder 14 applied thereon for forming a substantially non-tackysurface 16. In the embodiment shown, the synthetic material 10 islayered upon release paper 20 such that a tacky surface 22 of thesynthetic material 10 is releasably supported upon the paper 20.

Base Material

Generally speaking, the base material of the present invention is atleast partially tacky at room temperature (e.g., about 23° C.) and isalso preferably tacky at temperatures between about 0° C. and about 80°C. Additionally, the base material preferably exhibits reinforcementcharacteristics (e.g., imparts rigity, stiffness, strength or acombination thereof to a member), acoustic characteristics (e.g.,absorbs sound), sealing characteristics or other advantageouscharacteristics. It is also preferable for the base material to be heatactivated to expand or otherwise activate and wet surfaces which thebase material contacts. After expansion or activation, the base materialpreferably cures, hardens and adheres to the surfaces that it contacts.It is preferable for the powder to have minimal detrimental effects uponthe adhesivity of the base material and it is contemplated that thepowder may enhance the adhesivity of the base material.

Depending on the purpose of the synthetic material, it is preferable forbase material to exhibit certain characteristics such that some or allof these characteristic may also be exhibited by the synthetic material.For application purposes, it is often preferable that the base materialexhibit flexibility, particularly when the base material is to beapplied to a contoured surface of an article of manufacture. Onceapplied, however, it is typically preferable for the base material to beactivatable to soften, expand (e.g., foam), cure, harden or acombination thereof. For example, and without limitation, a typical basematerial will include a polymeric material, such as an epoxy resin orethylene-based polymer which, when compounded with appropriateingredients (typically a blowing and curing agent), expands and cures ina reliable and predicable manner upon the application of heat or theoccurrence of a particular ambient condition. From a chemical standpointfor a thermally-activated material, the base material may be initiallyprocessed as a flowable material before curing. Thereafter, the basematerial preferably cross-links upon curing, which makes the materialsubstantially incapable of further flow.

In most applications, it is undesirable for the base material to bereactive at room temperature or otherwise at the ambient temperature ina manufacturing environment (e.g. up to about 40° C. or higher). Moretypically, the base material becomes reactive at higher processingtemperatures, such as those encountered in an automobile assembly plant.In such and embodiment, the base material may be foamed upon automobilecomponents at elevated temperatures or at higher applied energy levels,e.g., during painting preparation steps. While temperatures encounteredin an automobile assembly operation may be in the range of about 148.89°C. to 204.44° C. (about 300° F. to 400° F.), body and paint shopapplications are commonly about 93.33° C. (about 200° F.) or slightlyhigher. If needed, blowing agent activators can be incorporated into thebase material to cause expansion at different temperatures outside theabove ranges.

Generally, suitable expandable materials or foams for the base materialhave a range of expansion ranging from approximately 0 to over 1000percent. The level of expansion of the material may be increased to ashigh as 1500 percent or more. Typically, strength is obtained frommaterials that undergo relatively low expansion while materials intendedfor acoustic use (e.g., damping) typically undergo greater expansion.

Advantageously, the base material of the present invention may be formedor otherwise processed in a variety of ways. For example, preferred basematerials can be processed by injection molding, extrusion, compressionmolding or with a robotically controlled extruder such as amini-applicator. This enables the formation and creation of part designsthat exceed the capability of most prior art materials.

It is contemplated that the base material may be formed of a variety ofmaterials. For example, and without limitation, the base material may beformed primarily of plastics, thermoplastics, epoxy materials,elastomers and the like or combination thereof.

In one embodiment, the base material may be elastomer-based. In such anembodiment, the base material may include or be primarily composed ofelastomers such as natural rubber, styrene-butadiene rubber,polyisoprene, polyisobutylene, polybutadiene, isoprene-butadienecopolymer, neoprene, nitrile rubber (e.g., a butyl nitrile, such ascarboxy-terminated butyl nitrile), butyl rubber, polysulfide elastomer,acrylic elastomer, acrylonitrile elastomers, silicone rubber,polysiloxanes, polyester rubber, diisocyanate-linked condensationelastomer, EPDM (ethylene-propylene diene rubbers), chlorosulphonatedpolyethylene, fluorinated hydrocarbons, combinations thereof and thelike. In one embodiment, recycled tire rubber may be employed. Examplesof suitable elastomer-based materials, which may be used as in the basematerial are sold under the product designations L2701, L2662, L2609 andare commercially available from L&L Products, Romeo, Mich. According tothe preferred formulations, the base material includes up to about 30%by weight elastomers, more preferably, up to about 40% by weightelastomers, and even more preferably up to about 60% by weightelastomers. Of course, the preferred amount of elastomer may varydepending upon the desired application of the synthetic material.

In other embodiments, it is contemplated that the base material may bethermoplastic-based. In such an embodiment the base material may includeor be primarily composed of thermoplastic materials such as polyamides,polyolefins, polyethylene, polyvinyl chlorides, polyproylene, ethylenecopolymers, terpolymers and the like and combinations thereof. Accordingto the preferred formulations, the base material includes up to about40% by weight thermoplastics, more preferably, up to about 60% by weightthermoplastics, and even more preferably up to about 80% by weightthermoplastics. Of course, like the elastomer formulations, the amountof thermoplastic may vary depending upon the desired application of thesynthetic material.

In a highly preferred embodiment, the base material is epoxy-based andincludes or is primarily composed of various epoxy containing materials.The base material may be formed from variety of formulations havingepoxy material and preferably epoxy resin integrated therein. Epoxyresin is used herein to mean any of the conventional dimeric, oligomericor polymeric epoxy materials containing at least one epoxy functionalgroup. The epoxy materials may be epoxy containing materials having oneor more oxirane rings polymerizable by a ring opening reaction.

The epoxy may be aliphatic, cycloaliphatic, aromatic or the like. Theepoxy may be supplied as a solid (e.g., as pellets, chunks, pieces orthe like) or a liquid. The epoxy may include an ethylene copolymer orterpolymer that may possess an alpha-olefin. As a copolymer orterpolymer, the polymer is composed of two or three different monomers,i.e., small molecules with high chemical reactivity that are capable oflinking up with similar molecules. One exemplary epoxy resin may be aphenolic resin, which may be a novalac type or other type resin. Otherpreferred epoxy containing materials may include a bisphenol-Aepichlorohydrin ether polymer, or a bisphenol-A epoxy resin which may bemodified with butadiene or another polymeric additive. Examples ofsuitable epoxy-based materials, which may be used as in the basematerial are sold under the product designations L5020, L5010, L5224,L8000, L5001 and are commercially available from L&L Products, Romeo,Mich. According to preferred formulations, the base material can includeup to about 50% by weight epoxy resins, more preferably, up to about 65%by weight epoxy resins, and even more preferably up to about 80% byweight epoxy resins.

In preferred embodiments, a substantial portion of the materials in thebase material will typically have molecular weights that are low enoughto maintain adhesive capability of the base material. For anelastomer-based or epoxy-based base material, it is preferable for atleast about 5% by weight of the elastomer or epoxy materials to have amolecular weight less than about 1000 and more preferably at least about10% by weight of the elastomer or epoxy materials have a molecularweight less than about 1000. It is also contemplated that, formaintaining adhesive capability, components such as plasticizers orprocessing oils may be added to elastomer-based or epoxy-based materialsand particularly to the thermoplastic-based base material.

As general guidance for the base material, it is preferable that atleast 1% by weight of the components have a low enough molecular weightto be a liquid at about 23° C. More preferably, at least 5% by weight ofthe components have a low enough molecular weight to be a liquid atabout 23° C. Still more preferably, at least 10% by weight of thecomponents have a low enough molecular weight to be a liquid at about23° C.

Powder

Generally, it is desirable for the powder to include components havinghigher molecular weights than the molecular weights of components in thebase material, but similar chemical structures. Such higher molecularweights can assist the powder to be substantially non-tacky at aboutroom temperature (e.g., around 23° C.) and higher temperatures (e.g., upto about 40° C., about 60° C. and even up to about 80° C.). Preferably,however, the powder has some adhesive properties at elevatedtemperatures such as temperatures greater than about 120° C., morepreferably greater than about 140° C. and most preferably greater than150° C. More specifically, the powder preferably has a glass transitionor activation temperature at or near the glass transition temperature oractivation temperature of the base material. Thus, the powder may becomeflowable and combine with the base material such that the powder, thereinforcement material or both can expand and/or adhere to a surface ofa structural member. Moreover, the powder is preferably non-inert orreactive (e.g., curable) along with other components of the powder orthe base material.

In highly preferred embodiments, the components of the powder includeone or a subset of correspondence components. As used herein,correspondence components are polymeric components in the powder thatcorrespond to polymeric components present in the base material. Acorrespondence component may be a component in the powder that issubstantially identical to a component in the base material. Forexample, the base material may include a bisphenol-A epoxy resin and thepowder may include the exact same bisphenol-A epoxy resin as acorrespondence component. Alternatively, a correspondence component maybe a component of the powder having a substantially identical monomer oroligomer configuration to it corresponding component in the basematerial, but the correspondence component may have a greater molecularweight or longer polymeric chain structure. As another alternative, acorrespondence component may be a component in the powder that is onlyinsubstantially different from its corresponding component in the basematerial (e.g., exhibits substantially the same characteristics, has atleast a similar polymeric structure, but has a higher molecular weight).

It is generally preferable for the powder to include a substantialproportion of correspondence components. In one embodiment, the powderincludes at least about 30% by weight correspondence components, morepreferably at least about 60% by weight correspondence components andeven more preferably at least about 70% by weight correspondencecomponents.

Molecular weights of the correspondence components may vary across areasonably large range. In a preferred embodiment, the molecular weightsof the correspondence components are between about 1000 and about10,000,000 and is more preferably between about 10,000 and about1,000,000. One example of suitable elastomeric correspondence componentis nitrile rubber such as copolymers of acrylonitrile and butadiene,which may be supplied as a liquid or a solid and which may or may not becarboxylated. Another example of a suitable correspondence component isethylene propylene diene monomer (EPDM) rubber, which also may besupplied as a solid or a liquid.

In a highly preferred embodiment, the synthetic material includes a basematerial that is formed of an epoxy-based material and a powder that isformed of an epoxy-based material. In the embodiment, the powder isformed of a combination of two or more of the following components: 1)epoxy resin; 2) thermoplastic (preferably epoxy-based); 3)elastomer-containing adduct; 4) curing agent; 5) catalyst; and 6) curingaccelerator. Preferably, the epoxy resin and epoxy-based thermoplasticare of sufficiently high molecular weight to be solid at about roomtemperature (e.g., about 23° C.). However, a relatively smaller amount(e.g. between about 5% and about 15% by weight of the powder) mayinitially be provided as a liquid epoxy resin.

Again, epoxy resin is used herein to mean any of the conventionaldimeric, oligomeric or polymeric epoxy materials containing at least oneepoxy functional group. The polymer-based materials may be epoxycontaining materials having one or more oxirane rings polymerizable by aring opening reaction. According to the preferred formulations, thepowder includes between about 30% and about 95% by weight epoxy resins,more preferably, between about 40% and about 85% by weight epoxy resins,and even more preferably between about 50% and about 75% by weight epoxyresins. For epoxy resins powders, correspondence components preferablycompose at least about 50% by weight of the powder, more preferably atleast about 60% by weight of the powder and even more preferably atleast about 70% by weight of the powder.

The epoxy may be aliphatic, cycloaliphatic, aromatic or the like. Theepoxy may be supplied as a solid (e.g., as pellets, chunks, pieces orthe like) or a liquid. The epoxy may include an ethylene copolymer orterpolymer that may possess an alpha-olefin. As a copolymer orterpolymer, the polymer is composed of two or three different monomers,i.e., small molecules with high chemical reactivity that are capable oflinking up with similar molecules. One exemplary epoxy resin may be aphenolic resin, which may be a novalac type or other type resin. Otherpreferred epoxy containing materials may include a bisphenol-Aepichlorohydrin ether polymer, or a bisphenol-A epoxy resin, which maybe modified with butadiene or another polymeric additive.

Examples of suitable thermoplastics may include, but are not limited to,polyamides, polyolefins, polyethylene, polyvinyl chlorides,polyproylene, ethylene copolymers and terpolymers, combinations thereofor the like. In one highly preferred embodiment, an epoxy-basedthermoplastic such as a polyhydroxyether or phenoxy resin is provided inthe powder. According to preferred formulations, the powder includesbetween about 2% and about 25% by weight thermoplastic resin, morepreferably, between about 5% and about 15% by weight thermoplasticresin, and even more preferably between about 9% and about 13% by weightthermoplastic resin.

In a highly preferred embodiment, an elastomer-containing adduct isemployed in the powder of the present invention. The epoxy/elastomerhybrid may be included in an amount of up to about 30% by weight of thepowder. More preferably, the elastomer-containing adduct isapproximately 3% to 20%, and more preferably is about 7% to 13% byweight of the powder. Additionally, the epoxy/elastomer hybrid may be acorrespondence component.

In turn, the adduct itself generally includes about 1:5 to 5:1 parts ofepoxy to elastomer, and more preferably about 1:3 to 3:1 parts or epoxyto elastomer. The elastomer compound may be any suitable art disclosedelastomer such as a thermosetting elastomer. Exemplary elastomersinclude, without limitation natural rubber, styrene-butadiene rubber,polyisoprene, polyisobutylene, polybutadiene, isoprene-butadienecopolymer, neoprene, nitrile rubber (e.g., a butyl nitrile, such ascarboxy-terminated butyl nitrile), butyl rubber, polysulfide elastomer,acrylic elastomer, acrylonitrile elastomers, silicone rubber,polysiloxanes, polyester rubber, diisocyanate-linked condensationelastomer, EPDM (ethylene-propylene diene rubbers), chlorosulphonatedpolyethylene, fluorinated hydrocarbons and the like. In one embodiment,recycled tire rubber is employed.

According to the preferred formulations, the powder includes betweenabout 3.0% and about 20.0% by weight curing agents, more preferably,between about 6.0% and about 15.0% by weight curing agents, and evenmore preferably between about 8.0% and about 10.0% by weight curingagents.

Preferably, the curing agents assist the powder, the reinforcementmaterial or both in curing by crosslinking of the polymers, epoxy resins(e.g., by reacting in stoichiometrically excess amounts of curing agentwith the epoxide groups on the resins) or both. Useful classes of curingagents are materials selected from aliphatic or aromatic amines or theirrespective adducts, amidoamines, polyamides, cycloaliphatic amines,(e.g., anhydrides, polycarboxylic polyesters, isocyanates, phenol-basedresins (such as phenol or cresol novolak resins, copolymers such asthose of phenol terpene, polyvinyl phenol, or bisphenol-A formaldehydecopolymers, bishydroxyphenyl alkanes or the like), or mixtures thereof.Particular preferred curing agents include modified and unmodifiedpolyamines or polyamides such as triethylenetetramine,diethylenetriamine tetraethylenepentamine, cyanoguanidine,dicyandiamides and the like. It is also contemplated that curing agentaccelerators may be included in the powder.

In various embodiment of the invention, one or more fillers may also beadded to the powder including, but not limited to, particulatedmaterials (e.g., powder), beads, microspheres, or the like. Preferably,the filler includes a relatively low-density material that is generallynon-reactive with the other components present in the powder. Fillersmay be present up to 70% by weight of the powder, but are morepreferably between about 15% and about 20% by weight of the powder.

Examples of fillers include silica, diatomaceous earth, glass, clay,nanoclay, talc, pigments, colorants, glass beads or bubbles, glass,carbon ceramic fibers, antioxidants, and the like. The clays that may beused as fillers may include clays from the kaolinite, illite, chloritem,smecitite or sepiolite groups, which may be calcined. Examples ofsuitable fillers include, without limitation, talc, vermiculite,pyrophyllite, sauconite, saponite, nontronite, montmorillonite ormixtures thereof. The clays may also include minor amounts of otheringredients such as carbonates, feldspars, micas and quartz. The fillersmay also include ammonium chlorides such as dimethyl ammonium chlorideand dimethyl benzyl ammonium chloride. Titanium dioxide might also beemployed.

Additional fillers may include mineral or stone type fillers such ascalcium carbonate, sodium carbonate or the like may be used as fillers.In another preferred embodiment, silicate minerals such as mica may beused as fillers.

Other additives may be included in the powder as well such as pigments,dyes or the like. In one preferred embodiment, the powder may includemetallic or other components for making the synthetic materialappropriate for weld-through operations. Examples of appropriateweld-through assisting additives include powdered carbon or graphite,metal compounds, metallic fibers, iron phosphate or the like. It isadditionally contemplated that such weld-through assisting additives maybe added to the base material.

Formation

Formation of the powder may be accomplished according to a variety oftechniques. According to one technique, the various components are mixedtogether at elevated temperatures (e.g., between about 80° C. to about150° C.) in a mixer (e.g., a double arm mixer, a Shaw or Bambury mixer,an extruder or the like). Preferably, the components are mixed, extrudedor the like to form the components into substantially homogenous pieces(e.g., chunks, pellets or the like). Thereafter, the pieces are groundinto a powder. Grinding of the pieces may be accomplished by varioustechniques including micro-pulverizing, hammer-milling, jet-milling orthe like. The preferred particle size of the powder is between about 10microns and about 1000 microns, more preferably between about 25 micronsand about 500 microns and even more preferably between about 50 micronsand 300 microns. Optionally, sieving processes may be employedintermittently or simultaneously with the grinding of the pieces toassure that substantially all the particles are of the desired size.

Once formed, the powder may be applied to the base material to form thesynthetic material using a variety of techniques. Depending on how thebase material is formed, the powder may be manually, automatically orotherwise applied to the base material. In preferred embodiments,however, the powder is automatically applied or dispensed to the basematerial by pouring, sifting, straining or the like.

Referring to FIG. 2, there is illustrated one preferred method offorming the synthetic material 10 of FIG. 1. As shown, the base material12 is applied (e.g., extruded) onto release paper 30 that is beingadvanced along a conveyor belt 34. In the embodiment shown, the basematerial is extruded via a single or twin screw extruder 38, although,the base material 12 may be otherwise applied. The base material 12 maybe applied, as desired, in various patterns, shapes or thicknesses ontothe release paper 30. Alternatively, the base material 12 may be appliedand then die cut or otherwise formed into a desired configuration.

After extrusion, the base material 12 is advanced along the conveyorbelt 34 below a sifter 44 from which the powder 14 is poured (e.g.,sifted) onto one or more surfaces of the base material 12 therebyforming a layer of the powder 14 on the base material 12. Preferably, aroller 48 or other compression system is provided for pressing thepowder 14 into intimate contact with the base material 12 to form thesynthetic material 10 such that the powder layer that has beensubstantially integrated into the base material 12 and such that thelayer of powder 14 provide the at least one substantially non-tackysurface 16.

For base material 12 that has been extruded or otherwise formed asdesired, one or more surfaces of the base material 12 may be covered(e.g., with release paper or otherwise) while the powder 14 is appliedto all exposed surfaces (e.g., surfaces not contacting the releasepaper). Advantageously, the powder 14 will then remove at least asubstantial portion of the tackiness or pressure sensitivity from eachof the exposed surfaces (e.g., including edges of the base material)such that no tacky surfaces are exposed during transport or otherwiseprior to application of the synthetic material.

As an added advantage, the powder of the present invention allows forthe recycling of the powder, the synthetic material or both. In thisregard, a portion of the powder that is applied or dispensed upon thebase material may not actually adhere to the base material.Advantageously, such powder may be collected by a vacuum system orotherwise and be reapplied to other base material. Moreover, certainexcess portions of the synthetic material, once formed, may be cut awayfrom or otherwise removed from the synthetic material during shaping orfurther processing of the synthetic material. Advantageously, theseexcess portions of the material may be recycled by introducing theportions into the extruder or other dispenser and forming more basematerial therewith. Moreover, the recycling of the synthetic materialdoes not significantly affect the properties of the base material beingformed since the powder is only a relatively small proportion of thesynthetic material and the powder is preferably formed of a subset ofthe materials of the base material (e.g., correspondence components).

Application

Generally, the synthetic material is applied to a member of an articleof manufacture. The member may be a structural member (e.g., a memberdesigned to withstand various loads) or another member. According to onepreferred embodiment, the member may be part of an automotive vehicle.For example, the member might be a frame member, a body member, abumper, a pillar, a panel, a support structure or the like of anautomotive vehicle.

Preferably, the synthetic material is applied directly to a member suchthat the material can provide reinforcement; acoustic damping, sealingor the like to the member or adjacent members. For application, anindividual or machine may remove (e.g., peel) the synthetic materialfrom the release paper to expose its tacky surface. Thereafter, theindividual or machine can place the tacky surface in contact with amember to adhere the synthetic material to the member. Once applied, thesynthetic material may be activated by heat or otherwise to expand andadhere to adjacent surfaces of various members of the article ofmanufacture. Advantageously, the non-tacky surface of the syntheticmaterial allows for case of initial contact and subsequent contact (e.g.for repositioning) with the non-tacky surface for application of thesynthetic material.

According to an alternative embodiment, the synthetic material may beapplied to a first member (e.g., a carrier member) for forming areinforcement member and then the reinforcement member may be applied toa member of an article of manufacture. In the embodiment, the tackysurface of the synthetic material is adhered to a surface of a carriermember (e.g., a skeleton member) with at least one exposed andpreferably substantially non-tacky surface facing at least partiallyaway from the surface of the carrier member thereby forming thereinforcement member. Advantageously, the non-tacky surface can allowfor easier placement of the reinforcement member adjacent to astructural member or for easier placement of the reinforcement memberwithin a cavity of the structural member of an article of manufacturesince the non-tacky surface does not undesirably adhere to surfaces ofthe structural member during placement. In a particular preferredembodiment, the carrier member could be formed of injection moldednylon, injection molded polymer, or molded metal (such as aluminum,magnesium, steel and titanium, an alloy derived from the metals, andeven a metallic foam).

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

What is claimed is:
 1. A synthetic material comprising: a base materialthat is tacky at a temperature of less than about 80° C., the basematerial providing at least one tacky surface; and a powder layered uponthe base material, the powder providing a substantially non-tackysurface at a temperature of up to about 40° C., the powder exhibitingadhesivity at a temperature greater than 120° C.; wherein the powderincludes one or more epoxy resin correspondence components.
 2. Asynthetic material as in claim 1 wherein the base material is selectedfrom the group consisting of a thermoplastic-based material, anepoxy-based material and an elastomer based material.
 3. A syntheticmaterial as in claim 1 wherein the one or more correspondence componentsare substantially identical to one or more components in the basematerial.
 4. A synthetic material as in claim 1 wherein the one or morecorrespondence components represent at least about 60% by weight of thepowder.
 5. A synthetic material as in claim 1 wherein the one or morecorrespondence components represent at least about 30% by weight of thepowder.
 6. A synthetic material comprising: a base material that istacky at a temperature of about 23° C. wherein: i) the base materialincluding an epoxy resin; and ii) the base material provides at leastone tacky surface; and a powder layer on the base material wherein: i)the powder provides a substantially non-tacky surface at a temperatureof about 23° C.; ii) the powder exhibits adhesivity at a temperaturegreater than 120° C.; and iii) the powder includes at least one or moreepoxy resin correspondence components.
 7. A synthetic material as inclaim 6 wherein the one or more epoxy correspondence components aresubstantially identical to one or more components in the base material.8. A synthetic material as in claim 7 wherein the one or morecorrespondence components represent at least about 30% by weight of thepowder.
 9. A synthetic material as in claim 8 wherein the one or morecorrespondence components represent at least about 60% by weight of thepowder.
 10. A synthetic material as in claim 1 wherein the base materialis an expandable material.
 11. A synthetic material as in claim 1wherein the base material includes a curing agent.
 12. A syntheticmaterial as in claim 1 wherein the base material includes a blowingagent.
 13. A synthetic material comprising: a base material that istacky at a temperature of less than about 80° C., the base materialproviding at least one tacky surface, the base material including acuring agent and a blowing agent; and a powder layered upon the basematerial, the powder providing a substantially non-tacky surface at atemperature of up to about 40° C., the powder exhibiting adhesivity at atemperature greater than 120° C.; wherein the powder induces one or moreepoxy resin correspondence components and the correspondence componentsare polymeric components in the powder that correspond to polymericcomponents present in the base material.
 14. A synthetic material as inclaim 13, wherein the correspondence components in the powder have asubstantially identical monomer or oligomer configuration to thepolymeric components in the base material with the exception that thecorrespondence components in the powder have a greater molecular weightor longer polymeric chain structure than the polymeric components in thebase material.